Modular seal system

ABSTRACT

A ring seal system includes a first segment having a first support member formed from a first support material, and a first seal portion mounted to the first support. The first seal portion is formed from a first seal material. A second segment includes a second support member formed from a second support material that is distinct from the first support material, and a second seal portion mounted to the second support. The second seal portion is formed from a second seal material distinct from the first seal material. The second segment is operatively connected to the first segment.

BACKGROUND

Downhole systems rely on a variety of seals to control flow and/or establish flow paths. One form of seal, such as a ring seal, may be selectively positioned along a first portion of a tubular and subsequently shifted to create a barrier. A ring seal may include a metal support, a first elastomer material arranged on one side of the metal support, and a second elastomer material arranged on a second, opposing side of the metal support. The ring seal may be run along a tapered surface of the tubular. Travel along the tapered surface causes the seal to expand and engage an adjacent structure.

Seals are exposed to a variety of operating conditions. Pressure, temperature, fluids as well as other factors can vary in each formation. Seals are selected to withstand a particular operating environment. Different materials employed in ring seals respond differently to these factors. One material may be better at higher temperature while another material may possess a good response at lower temperatures. Different materials used in the metal support may also possess different qualities such as strength, resilience, and corrosion resistance.

SUMMARY

A ring seal system includes a first segment having a first support member formed from a first support material, and a first seal portion mounted to the first support. The first seal portion is formed from a first seal material. A second segment includes a second support member formed from a second support material that is distinct from the first support material, and a second seal portion mounted to the second support. The second seal portion is formed from a second seal material distinct from the first seal material. The second segment is operatively connected to the first segment.

A resource exploration system includes a surface system, and a downhole system operatively connected to the surface system through a system of tubulars. At least one of the system of tubulars supports a ring seal system including a first segment having a first support member formed from a first support material, and a first seal portion mounted to the first support. The first seal portion is formed from a first seal material. A second segment includes a second support member formed from a second support material that is distinct from the first support material, and a second seal portion mounted to the second support. The second seal portion is formed from a second seal material distinct from the first seal material. The second segment is operatively connected to the first segment.

BRIEF DESCRIPTION OF THE DRAWINGS

Referring now to the drawings wherein like elements are numbered alike in the several Figures:

FIG. 1 depicts a resource exploration system including a modular seal system, in accordance with an exemplary embodiment;

FIG. 2 depicts a cross-sectional view of the modular seal system arranged between a first tubular and a second tubular, in accordance with the exemplary embodiment, arranged therebetween;

FIG. 3 depicts a detail view of the modular seal system of FIG. 2; and

FIG. 4 depicts a cross-sectional view of a modular seal system, in accordance with another aspect of an exemplary embodiment, arranged between a first tubular and a second tubular.

DETAILED DESCRIPTION

A resource exploration system, in accordance with an exemplary embodiment, is indicated generally at 2, in FIG. 1. Resource exploration system 2 should be understood to include well drilling operations, resource extraction and recovery, CO₂ sequestration, and the like. Resource exploration system 2 may include a surface system 4 operatively connected to a downhole system 6. Surface system 4 may include pumps 8 that may aid in treatment, completion and/or extraction processes, as well as a fluid storage zone 10. Fluid storage zone 10 may contain a gravel pack fluid or slurry (not shown), a fracturing fluid (also not shown), or a treating fluid that may be introduced into downhole system 6.

Downhole system 6 may include a system of tubulars 20 that is extended into a wellbore 21 formed in formation 22. System of tubulars 20 may include a first tubular (not separately labeled) which may take the form of an outer tubular 26 and a second tubular (also not separately labeled) which may take the form of an inner tubular 28. An annular or ring seal system 34 is arranged between first tubular 26 and second tubular 28. It is to be understood that the relative position of ring seal system 34 may vary. As shown in FIGS. 2 and 3, first tubular 26 includes an outer surface 39 and an inner surface 40. Second tubular 28 includes an outer surface portion 42 and an inner surface portion 43. Second tubular 28 is also shown to include a cone portion 46 having a conical surface portion. 48.

In accordance with an aspect of an exemplary embodiment, ring seal system 34 includes a first segment 60, a second segment 62 a third segment 64, a fourth segment 66, and a fifth segment 68. It is to be understood that the number of segments may vary. First segment 60 includes a first support member 72 defining an annular or substantially annular ring formed from a first support material 74. First support material 74 may take the form of an expandable metal such as, for example, an annealed nickel alloy, 80 ksi 4140, or a nickel based molybdenum or nickel based chromium and molybdenum steel alloys. First support member 72 includes a first base portion 76, a first end portion 78. First base portion 76 includes a first recess 80. A first O-ring 82 is arranged in first recess 80. First end portion 78 includes a first recess portion 84. A first seal portion 86 is arranged in first recess portion 84. First seal portion 86 is formed from a first seal material 88. First seal material 88 may take the form of, for example, about a 90 durometer perfluoroelastomer (FFKM).

Second segment 62 includes a second support member 92 operatively connected to first segment 60. The term operatively connected should be understood to describe that first segment 60 and second segment 62 are adjoined or may be connected through mechanical and/or chemical processes. Second support member 92 defines annular or substantially annular ring formed from a second support material 94. Second support material 94 may take the form of an expandable metal such as, for example, an annealed 8620 steel. Second support member 92 includes a second base portion 96, and a second end portion 98. Second base portion 96 includes a second recess 100. A second O-ring 102 is arranged in second recess 100. Second end portion 98 includes a second recess portion 104. A second seal portion 106 is arranged in second recess portion 104. Second seal portion 106 is formed from a second seal material 108. Second seal material 108 may take the form of, for example, about an 80 durometer fluoroelastomer (FKM).

Third segment 64 includes a third support member 112 operatively connected to second segment 62. It is to be understood that operatively connected to second segment 62 does not require a direct contact. Third segment 64 may be adjoined to first segment 60 which, in turn, may be adjoined to second segment 62. Operatively connected should be understood to describe that segments form part of the same annular seal. Third support member 112 defines annular or substantially annular ring formed from a third support material 114. Third support material 114 may take the form of an expandable metal such as, for example, an annealed aluminum alloy. Third support member 112 includes a third base portion 116, and a third end portion 118. Third base portion 116 includes a third recess 120. A third O-ring 122 is arranged in third recess 120. Third end portion 118 includes a third recess portion 124. A third seal portion 126 is arranged in third recess portion 124. Third seal portion 126 is formed from a third seal material 128. Third seal material 128 may take the form of, for example, about a 70 durometer hydrogenated nitrile butadiene rubber (HNBR).

Fourth segment 66 includes a fourth support member 132 operatively connected to third segment 64. Fourth support member 132 defines annular or substantially annular ring formed from a fourth support material 134. Fourth support material 134 may be the same or substantially the same as second support material 94 or may be formed from a different expandable metal depending upon desired operational characteristics. Fourth support member 132 includes a fourth base portion 136, and a fourth end portion 138. Fourth base portion 136 includes a fourth recess 140. A fourth O-ring 142 is arranged in fourth recess 140. Fourth end portion 138 includes a fourth recess portion 144. A fourth seal portion 146 is arranged in fourth recess portion 144. Fourth seal portion 146 is formed from a fourth seal material 148. Fourth seal material 148 may be the same as or substantially the same as second seal material 108 or may take on another form depending upon desired sealing characteristics.

Fifth segment 68 includes a fifth support member 152 operatively connected to fourth segment 66. Fifth support member 152 defines annular or substantially annular ring formed from a fifth support material 154. Fifth support material 154 may be the same or substantially the same as first support material 74 or may be formed from a different expandable metal depending upon desired operational characteristics. Fifth support member 152 includes a fifth base portion 156, and a fifth end portion 158. Fifth base portion 156 includes a fifth recess 160. A fifth O-ring 162 is arranged in fifth recess 160. Fifth end portion 158 includes a fifth recess portion 164. A fifth seal portion 166 is arranged in fifth recess portion 164. Fifth seal portion 166 is formed from a fifth seal material 168. Fifth seal material 168 may be the same as or substantially the same as first seal material 88 or may take on another form depending upon desired sealing characteristics.

In accordance with an exemplary aspect, segments may include additional features such as shown in FIG. 4. For example, a first segment 190 includes a first support member 192 that may be formed from a first support material 194 such as described above. First segment 190 includes a tab 196 extending axially outwardly from first support member 192. A second segment 200 includes a second support member 202 that may be formed from a second support material 204 such as described above. Second segment 200 includes a recess 206 extending axially inwardly to second support member 202. Tab 196 may extend into recess 206 and mechanically connect with second segment 200. Additionally, second support member 202 may include an end portion 208 provided with a recess portion 210. Recess portion 210 receives and supports a seal portion 212. In the exemplary embodiment shown, a rib 214 projects radially outwardly of end portion 208. Rib 214 promotes and enhances retention of seal portion 212.

It is to be understood that exemplary embodiments describe a composite annular seal formed from various materials that may be tailored to specific downhole applications. Portions or segments of the seal may expand at different rates, seal at different temperatures and/or be capable of withstanding different pressures. In this manner, the seal may readily adapt to changing downhole conditions and reduce failure modes that could otherwise require costly repair, removal and maintenance. Additionally, it is to be understood that the number of segments forming the composite annular seal may vary.

The teachings of the present disclosure may be used in a variety of well operations. These operations may involve using one or more treatment agents to treat a formation, the fluids resident in a formation, a wellbore, and/or equipment in the wellbore, such as production tubing. The treatment agents may be in the form of liquids, gases, solids, semi-solids, and mixtures thereof. Illustrative treatment agents include, but are not limited to, fracturing fluids, acids, steam, water, brine, anti-corrosion agents, cement, permeability modifiers, drilling muds, emulsifiers, demulsifiers, tracers, flow improvers etc. Illustrative well operations include, but are not limited to, hydraulic fracturing, stimulation, tracer injection, cleaning, acidizing, steam injection, water flooding, cementing, etc.

Embodiment 1

A ring seal system comprising: a first segment including a first support member formed from a first support material, and a first seal portion mounted to the first support, the first seal portion being formed from a first seal material; and a second segment including a second support member formed from a second support material that is distinct from the first support material, and a second seal portion mounted to the second support, the second seal portion being formed from a second seal material distinct from the first seal material, the second segment being operatively connected to the first segment.

Embodiment 2

The ring seal system according to embodiment 1, further comprising: a third segment including a third support member formed from a third support material that is distinct from at least one of the first support material and the second support material, and a third seal portion mounted to the third support, the third seal material being formed from a third seal material that is distinct from at least one of the first seal material and the second seal material, the third segment being operatively connected to at least one of the first segment and the second segment.

Embodiment 3

The ring seal system according to embodiment 2, wherein the third support material is distinct from each of the first support material and the second support material.

Embodiment 4

The ring seal system according to embodiment 2, wherein the third seal material is distinct from each of the first seal material and the second seal material.

Embodiment 5

The ring seal system according to embodiment 2, wherein the second segment directly abuts the first segment and the third segment directly abuts the second segment.

Embodiment 6

The ring seal system according to embodiment 5, further comprising: a fourth segment including a fourth support member formed from a fourth support material that is similar to the second support material, and a fourth seal portion mounted to the fourth support, the fourth seal portion being formed from a fourth seal material that is similar to the second seal material, the fourth segment directly abutting the third segment.

Embodiment 7

The ring seal system according to embodiment 6, further comprising: a fifth segment including a fifth support member formed from a fifth support material that is similar to the first support material, and a fifth seal portion mounted to the fifth support, the fifth seal portion being formed from a fifth seal material that is similar to the first seal material, the fifth segment directly abutting the fourth segment.

Embodiment 8

The ring seal system according to embodiment 1, wherein the second segment is mechanically linked to the first segment.

Embodiment 9

A resource exploration system comprising: a surface system; and a downhole system operatively connected to the surface system through a system of tubulars, at least one of the system of tubulars supporting a ring seal system comprising: a first segment including a first support member formed from a first support material, and a first seal portion mounted to the first support, the first seal portion being formed from a first seal material; and a second segment including a second support member formed from a second support material that is distinct from the first support material, and a second seal portion mounted to the second support, the second seal portion being formed from a second seal material distinct from the first seal material, the second segment being operatively connected to the first segment.

Embodiment 10

The resource exploration system according to embodiment 9, further comprising: a third segment including a third support member formed from a third support material that is distinct from at least one of the first support material and the second support material, and a third seal portion mounted to the third support, the third seal material being formed from a third seal material that is distinct from at least one of the first seal material and the second seal material, the third segment being operatively connected to at least one of the first segment and the second segment.

Embodiment 11

The resource exploration system according to embodiment 10, wherein the third support material is distinct from each of the first support material and the second support material.

Embodiment 12

The resource exploration system according to embodiment 10, wherein the third seal material is distinct from each of the first seal material and the second seal material.

Embodiment 13

The resource exploration system according to embodiment 10, wherein the second segment directly abuts the first segment and the third segment directly abuts the second segment.

Embodiment 14

The resource exploration system according to embodiment 13, further comprising: a fourth segment including a fourth support member formed from a fourth support material that is similar to the second support material, and a fourth seal portion mounted to the fourth support, the fourth seal portion being formed from a fourth seal material that is similar to the second seal material, the fourth segment directly abutting the third segment.

Embodiment 15

The resource exploration system according to embodiment 14, further comprising: a fifth segment including a fifth support member formed from a fifth support material that is similar to the first support material, and a fifth seal portion mounted to the fifth support, the fifth seal portion being formed from a fifth seal material that is similar to the first seal material, the fifth segment directly abutting the fourth segment.

The term “about” is intended to include the degree of error associated with measurement of the particular quantity based upon the equipment available at the time of filing the application. For example, “about” can include a range of ±8% or 5%, or 2% of a given value.

While one or more embodiments have been shown and described, modifications and substitutions may be made thereto without departing from the spirit and scope of the invention. Accordingly, it is to be understood that the present invention has been described by way of illustrations and not limitation. 

1. A ring seal system comprising: a first segment including a first support member formed from a first support material, and a first seal portion mounted to the first support, the first seal portion being formed from a first seal material; and a second segment including a second support member formed from a second support material that is distinct from the first support material, and a second seal portion mounted to the second support, the second seal portion being formed from a second seal material distinct from the first seal material, the second segment being operatively connected to the first segment.
 2. The ring seal system according to claim 1, further comprising: a third segment including a third support member formed from a third support material that is distinct from at least one of the first support material and the second support material, and a third seal portion mounted to the third support, the third seal material being formed from a third seal material that is distinct from at least one of the first seal material and the second seal material, the third segment being operatively connected to at least one of the first segment and the second segment.
 3. The ring seal system according to claim 2, wherein the third support material is distinct from each of the first support material and the second support material.
 4. The ring seal system according to claim 2, wherein the third seal material is distinct from each of the first seal material and the second seal material.
 5. The ring seal system according to claim 2, wherein the second segment directly abuts the first segment and the third segment directly abuts the second segment.
 6. The ring seal system according to claim 5, further comprising: a fourth segment including a fourth support member formed from a fourth support material that is similar to the second support material, and a fourth seal portion mounted to the fourth support, the fourth seal portion being formed from a fourth seal material that is similar to the second seal material, the fourth segment directly abutting the third segment.
 7. The ring seal system according to claim 6, further comprising: a fifth segment including a fifth support member formed from a fifth support material that is similar to the first support material, and a fifth seal portion mounted to the fifth support, the fifth seal portion being formed from a fifth seal material that is similar to the first seal material, the fifth segment directly abutting the fourth segment.
 8. The ring seal system according to claim 1, wherein the second segment is mechanically linked to the first segment.
 9. A resource exploration system comprising: a surface system; and a downhole system operatively connected to the surface system through a system of tubulars, at least one of the system of tubulars supporting a ring seal system comprising: a first segment including a first support member formed from a first support material, and a first seal portion mounted to the first support, the first seal portion being formed from a first seal material; and a second segment including a second support member formed from a second support material that is distinct from the first support material, and a second seal portion mounted to the second support, the second seal portion being formed from a second seal material distinct from the first seal material, the second segment being operatively connected to the first segment.
 10. The resource exploration system according to claim 9, further comprising: a third segment including a third support member formed from a third support material that is distinct from at least one of the first support material and the second support material, and a third seal portion mounted to the third support, the third seal material being formed from a third seal material that is distinct from at least one of the first seal material and the second seal material, the third segment being operatively connected to at least one of the first segment and the second segment.
 11. The resource exploration system according to claim 10, wherein the third support material is distinct from each of the first support material and the second support material.
 12. The resource exploration system according to claim 10, wherein the third seal material is distinct from each of the first seal material and the second seal material.
 13. The resource exploration system according to claim 10, wherein the second segment directly abuts the first segment and the third segment directly abuts the second segment.
 14. The resource exploration system according to claim 13, further comprising: a fourth segment including a fourth support member formed from a fourth support material that is similar to the second support material, and a fourth seal portion mounted to the fourth support, the fourth seal portion being formed from a fourth seal material that is similar to the second seal material, the fourth segment directly abutting the third segment.
 15. The resource exploration system according to claim 14, further comprising: a fifth segment including a fifth support member formed from a fifth support material that is similar to the first support material, and a fifth seal portion mounted to the fifth support, the fifth seal portion being formed from a fifth seal material that is similar to the first seal material, the fifth segment directly abutting the fourth segment. 